ML20099H502

Anonymous Affidavit Supporting Jl Mcdermott & Tj O'Neill 840731 Petition Re Deficiencies W/Engineering Practices on Large Bore Piping & Pipe Supports

ML20099H502
Person / Time
Site:	Diablo Canyon
Issue date:	02/06/1985
From:	GOVERNMENT ACCOUNTABILITY PROJECT
To:
Shared Package
ML20099H479	List: ML20099H476 ML20099H502 ML20099H527 ML20099H559 ML20099H574 ML20099H606 ML20099H626 ML20099H649 ML20099H663 ML20099H728 ML20099H754 ML20099H775
References
2.206, NUDOCS 8503190392
Download: ML20099H502 (6)

Text

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Exhibit 1

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UNITED STATES OF AMERICA NUCLEAR REGULATORY COMMISSION ERiGCE thg Ngg[ ggt 8ggg[g(gty Cgmg[gg{gg

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In the Matter of )

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PACIFIC GAS AND ELECTRIC ) Docket Nos. 50-275 COMPANY ) 50-323

)

Diablo Canyon Nuclear Power )

Plant, Units 1 and 2 )

)

AFFIDA's IT OF STATE OF CALIFORNIA SS COUNTY OF ALAMEDA

. CITY OF DERkELEY lhe above, being duly sworn, deposes and says:

My name is I am submitting this affidavit frecly and vol cntaril y , without any threats, inducements or coercion, to Mr. Thomas Devine, who has identified himself to me au the legal director of the Government Accountability Project (OAF). I am submitting this affidavit to evidence my personal lenowledge of deficiencies with engineering practices on large bore piping and pipe supports at the Diablo Canyon nuclear power plant. Dased on my review of Nuclear Regulatory Commission (NRC) inspector Isa Yin's comments in Diablo Canyon Supplemental Safety Evaluetton No. 25, I believe that I am one of the persons he would have sought to question had he been allowed to complete his irvestigation. I was in a position to be directly aware of the B503190392 850314 PDR ADOCK 05000275 O PDR , _

engineering practices'in question.

I have instructed Mr. Devine to transmit my affidavit to the NRC staff but to remove my name. Because I am actively employed within my profession as a Registered Professional Engineer, I have a lot to lose from retaliation. For that reason, this statement lists issues but does not provide supporting details or specific referances that could be traced back to me. Similarly, certain issues are not included for that same reason. I will fill in those holes during further correspondence with the NRC staff after assuring myself that my identity will be protected.

In some cases, the issues may appear duplicative of prior allegations, because I have presen'ted them in a generalized fashion to protect my anonymity. In further correspondence with a

the tiRC stafi I will provide further details necessary to assess whether en identical allegation already has been resolved, and whether my own conteibution would affect the prior, resolution. .

Further 1 have instructed Mr. Devine to withdraw this affidavit if my anonymi ty cannot be protected.

I. OVERVIEW

1. On balance, the report of NRC inspector Isa Yin 'on Diablo Canyon was accurate with respect to off-site consultant (s), but it failed to provide specific findings that matched the systematic scope of the quality assurance (OA) breakdown with respect to engineering work.

II. DESIGN ERRORS

2. The engineering calculations of off-site consultant (s) contained an unacceptable high rate of mistakes, including a high 2 .

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rate of significant errors and some error in all but a few of the packages.

3. Due to the use of the wrong formula, engineering calculations for Diablo Canyon may have under estimated the stresses in welds attaching baseplates to structural steel channels and angles where torsional or twisting force was applied, to the extent that hangers which passed should have failed.

4. In using the STRUDL computer program used #cr Diablo Canyon there was much confusion regarding the orientation of the principel axis of beam elements. This confusion resulted in the beam elements on occasion being oriented 90 degrees from where they were orientated in fact.

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5. In using the STRUDL computer program used for Diablo Canyon 6. h e use of defaults for the unbraced length of beam members on occasion resulted in an over estimation of the allowablo loads. This unconservative error could overestimate the allowable loads by up to 400%.

6. Due to insufficiently precine modeling in the use of the S1RUDL computer program used for Diablo Canyon, stresses on baseplates may be underestimated by 50% or more because the location at which the stresses were calculated differed from the location of manimum stress.

7. Decpite knowledge of inaccuracies in the STRUDL l

computer program for Diablo Canyon, management at off-site cotiuul tant (s) told employees to continue using the program as it was until instructed otherwise by Diablo Canyon Project i

Organi:ation (DCPO), which in some cases meant that the errors 3

were repeated indefinitely.

8. Based on International Congress of Building Officials Research Report No. 2156 and statements by Hilti personnel the use of expansion concrete anchors in areas subject to vibratory or shock loads is inappropriate. Since all power plants generate vibrations in piping during normal operation there use at Diablo Canyon is questionable.

9. The M-9 design guide for Diablo Canyon mistakenly allows allowable stresses approaching yield while only requiring that the members be designed to elastic criteria. If these higher allowables are to be allowed then the plastic design requirements in the AISC code should be required. Failure to meet these plastic design requirements could preclude the members from carrying the req'uired loads,

10. Due to an error in the M-9 design guide used to calculate allowable stresses, pipe supports throughout Diablo Canyon may be underdesigned to only withstand 89% of the stresses from a Hosgri earthquake, which could lead to mass failures if such an earthquake occured.

III. PROGRAM WEAKNESSES 11.

Off-site consultant (s) worked to uncontrolled documents on a generic basis, because Bechtel and PGt<E sent them documents without letters of transmittal to assure that the documents were current when sent and were regularly updated.

12. There was consi derabl e confusion by off-site consultants as to the Diablo Canyon Project Office (DCPO) standards for acceptable calculation packages, which raises 4

~

.I questions whether DCPO procedures P-6 and I-26 were transmitted to the consultant (s) in a timely manner.

13. There was heav,y emphasis on procuction pressure at off-site consultant (s) that could override quality concerns, to the extent that quotas were imposed on the number of packages that had to be processed daily.

14.

Personnel at of f-si te consultant (s) often assumed their responsibilities for extended periods prior to recieving any quality assurance indoctrination.

15. Quality assurance surveillance activities at off-site consultant (s) were inadequate, because they only occured on an erratic bacis and were skipped for extended periods of time.

16. Quality assurence auditing activities at off-site consultant (s) were inadequate, because they failed to check for the full extent of prior errors that could be represented by specific findings.

As mentioned earlier, I will provide further issues and details on the allegations above, if the NRC chooses to correspond with me on these concerns. If there is such a correspondence, I request that the NRC contact me through Mr.

Devine.

I have read the above 5-page affidavit, and it i s true accurate and complete to the best of my knowledge and belief.

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